Pickface builder for storage and retrieval systems

ABSTRACT

A pickface builder for a storage and retrieval system for storing goods units and having an in-feed conveyor and a picking device, each goods unit holding at least one product package therein, the pickface builder including a frame, a pusher member movably coupled to the frame, and a snugger member movably coupled to the frame, wherein the pickface builder is configured to receive goods units from the in-feed conveyor and the pusher member and snugger member are movable at least in a direction transverse to a direction of goods unit travel on the in-feed conveyor and configured to form the goods units into a pickface picked by the picking device as a unit and having a predetermined reference datum relating the pickface to a placement position of goods units forming the pickface along a storage surface of the storage and retrieval system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims the benefit of U.S.Provisional Patent Application No. 61/423,242 filed on Dec. 15, 2010,the disclosure of which is incorporated herein by reference in itsentirety.

BACKGROUND

1. Field

The embodiments generally relate to material handling systems and, moreparticularly, to automated storage and retrieval systems.

2. Brief Description of Related Developments

Warehouses for storing case units may generally comprise a series ofstorage racks that are accessible by transport devices such as, forexample, fork lifts, carts and elevators that are movable within aislesbetween or along the storage racks or by other lifting and transportingdevices. These transport devices may be automated or manually driven.Generally, where the case units are stored in multilevel racks, caseunits are placed on the different levels of the racks with a liftingdevice on the transport device. Where the case units are stored in rackslocated on different floors or levels of the storage structure the caseunits are generally transported between the floors while disposed on thetransport devices where the transport devices travel up and down rampsspanning between the floors. In other examples the transport device withthe case units disposed thereon are raised and lowered between thefloors with an elevator. Generally, the case units carried by thetransport devices and stored on the storage racks are contained incarriers, for example storage containers such as trays, totes orshipping cases, or on pallets. Generally, incoming pallets to thewarehouse (such as from manufacturers) contain shipping containers (e.g.cases) of the same type of goods. Outgoing pallets leaving thewarehouse, for example, to retailers have increasingly been made of whatmay be referred to as mixed pallets. As may be realized, such mixedpallets are made of shipping containers (e.g. totes or cases such ascartons, etc.) containing different types of goods. For example, onecase on the mixed pallet may hold grocery products (soup can, soda cans,etc.) and another case on the same pallet may hold cosmetic or householdcleaning or electronic products. Indeed some cases may hold differenttypes of products within a single case. Conventional warehousingsystems, including conventional automated warehousing systems do notlend themselves to efficient generation of mixed goods pallets. Inaddition, storing case units in, for example carriers, totes, trays oron pallets generally does not allow for the retrieval of individual caseunits within those carriers or pallets without transporting the carriersor pallets to a workstation for manual or automated removal of theindividual case units.

It would be advantageous to be able to transport uncontained orunpalletized case units between levels of a storage facility independentof transport device movement between the levels.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodimentsare explained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 schematically illustrates an exemplary storage and retrievalsystem in accordance with the embodiments;

FIGS. 2A, 2B, 2C, 2D, 3A and 3B illustrate schematic views of a conveyorsystem in accordance with the embodiments;

FIG. 4 illustrates a schematic view of a conveyor shelf in accordancewith the embodiments;

FIG. 5 schematically illustrates a conveyor system in accordance withthe embodiments;

FIGS. 6A-6D schematically illustrate a transfer station in accordancewith the embodiments;

FIG. 7 is a schematic illustration of a method in accordance with theembodiments;

FIG. 8 is a flow diagram of a method in accordance with the embodiments;

FIGS. 9A and 9B illustrate a feed station in accordance with theembodiments;

FIG. 10 illustrates a pickface builder in accordance with theembodiments;

FIG. 11 illustrates a pickface builder in accordance with theembodiments;

FIG. 12 illustrates a pickface builder in accordance with theembodiments;

FIGS. 13A-13H and 14A-14C are schematic illustrations of exemplaryoperations of a portion of the storage and retrieval system inaccordance with the exemplary embodiments;

FIG. 15 illustrates a platform in accordance with the embodiments;

FIG. 16 illustrates platform guides in accordance with the embodiments;and

FIG. 17 illustrates platform guides in accordance with the embodiments.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S)

FIG. 1 generally schematically illustrates a storage and retrievalsystem 100 in accordance with the embodiments. Although the disclosedembodiments will be described with reference to the embodiments shown inthe drawings, it should be understood that the disclosed embodiments canbe embodied in many alternate forms. In addition, any suitable size,shape or type of elements or materials could be used.

In accordance with the embodiments the storage and retrieval system 100may operate in a retail distribution center or warehouse to, forexample, fulfill orders received from retail stores for case units(where case units as used herein means items not stored in trays, ontotes or on pallets, e.g. uncontained or items stored in trays, totes oron pallets). It is noted that the case units may include cases of items(e.g. case of soup cans, boxes of cereal, etc.) or individual items thatare adapted to be taken off of or placed on a pallet. In accordance withthe embodiments, shipping cases or case units (e.g. cartons, barrels,boxes, crates, jugs, or any other suitable device for holding items) mayhave variable sizes and may be used to hold items in shipping and may beconfigured so they are capable of being palletized for shipping. It isnoted that when, for example, pallets of items arrive at the storage andretrieval system the content of each pallet may be uniform (e.g. eachpallet holds a predetermined number of the same item—one pallet holdssoup and another pallet holds cereal) and as pallets leave the storageand retrieval system the pallets may contain any suitable number andcombination of different items (e.g. each pallet may hold differenttypes of items—a pallet holds a combination of soup and cereal). In theembodiments the storage and retrieval system described herein may beapplied to any environment in which items (e.g. goods units holding atleast one product package therein) are stored and retrieved.

The storage and retrieval system 100 may be configured for installationin, for example, existing warehouse structures or adapted to newwarehouse structures. In the embodiments, the storage and retrievalsystem 100 may be substantially similar to that described in, forexample, U.S. Provisional Patent Application No. 61/423,340 filed onDec. 15, 2010, and U.S. patent application Ser. No. 13/326,674) filed onDec. 15, 2011), and U.S. patent application Ser. No. 12/757,381, filedon Apr. 9, 2010, (now U.S. Pat. No. 8,740,538), the disclosures of whichare incorporated herein by reference in their entireties. In oneexample, the storage and retrieval system 100 may include in-feed andout-feed transfer devices, such as stations 170, 160, multilevelvertical conveyors or picking devices 150A, 150B (MVCs), a storagestructure 130, and a number of autonomous vehicular transport robots 110(referred to herein as “bots”) that may also operate as transferdevices. In the embodiments the storage and retrieval system may alsoinclude transfer devices including robot or bot transfer stations 140(FIGS. 6A-6D) that may provide an interface between the bots 110 and themultilevel vertical conveyors 150A, 150B. In the embodiments, anysuitable transfer device may be provided at any location and on eitherside or level of MVC 150A, 150B to remove or pick material from orreplace or place material to MVC 150A, 150B at any shelf or platformlevel or location or otherwise. The in-feed transfer stations 170 andout-feed transfer stations 160 may operate together with theirrespective multilevel vertical conveyors 150A, 150B for transferringitems to and from one or more levels of a multi-level storage structure130. It is noted that while the multilevel vertical conveyors aredescribed herein as being dedicated inbound conveyors 150A and outboundconveyors 150B, in the embodiments each of the conveyors 150A, 150B maybe used for both inbound and outbound transfer of case units/items fromthe storage and retrieval system. It is noted that while multilevelvertical conveyors are described herein in other aspects the conveyorsmay be any suitable conveyors or transfer/picking devices having anysuitable transport path orientation. Bots 110 may be disposed on eachlevel of the multi-level storage structure 130 so that the bots 110 on arespective level can traverse an entirety of that level. The bots 110may be configured to place items, such as the above described retailmerchandise, into picking stock as described in U.S. patent applicationSer. No. 12/757,312, filed on Apr. 9, 2010, (now U.S. Pat. No.8,425,173), the disclosure of which is herein incorporated by referencein its entirety. Other suitable examples of bots are described in, forexample, U.S. Provisional Patent Application No. 61/423,220 filed onDec. 15, 2010 (U.S. application Ser. No. 13/327,040 filed on Dec. 15,2011, (now U.S. Pat. No. 9,187,244), U.S. patent application Ser. No.14/942,717 filed on Nov. 16, 2015, U.S. Provisional Patent ApplicationNo. 61/423,365 filed on Dec. 15, 2010, U.S. patent application Ser. No.13/326,952 filed on Dec. 15, 2011, U.S. Provisional Patent ApplicationNo. 61/423,359 filed on Dec. 15, 2010 (U.S. patent application Ser. No.13/326,447 filed on Dec. 15, 2011, (now U.S. Pat. No. 8,965,619), andU.S. Provisional Patent Application No. 61/423,388) filed on Dec. 15,2010 U.S. application Ser. No. 13/326,993 filed on Dec. 15, 2011, thedisclosures of which are incorporated herein by reference in theirentireties. In the embodiments, the bots 110 may be configured tointerface directly with the shelves of the multilevel vertical conveyors150A, 150B. In the embodiments the bots 110 may interface indirectlywith the multilevel vertical conveyors 150A, 150B through, for example,bot transfer stations 140 disposed on a respective level of themulti-level storage structure 130.

As described above, the storage structure 130 may include multiplelevels of storage rack modules where, in the embodiments, each levelincludes respective picking aisles 130A and at least one transfer deck130B for allowing the bots 110 to traverse respective levels of thestorage structure 130 for transferring case units between any of thestorage areas of the storage structure 130 and any shelf of anymultilevel vertical conveyor 150A, 150B. The picking aisles 130A, andtransfer decks 130B also allow the bots 110 to place case units intopicking stock and to retrieve ordered case units. In the embodimentseach level may include bot transfer stations 140 for allowing theexchange of items between the multilevel vertical conveyors 150A, 150Band a bot on a respective storage level of the storage structure 130.The storage structure 130 may be substantially similar to the storagestructure described in U.S. Provisional Patent Application No.61/423,340 filed on Dec. 15, 2010, U.S. patent application Ser. No.13/326,674 filed on Dec. 15, 2011, U.S. patent application Ser. No.12/757,381 filed on Apr. 9, 2010 (now U.S. Pat. No. 8,740,538), U.S.patent application Ser. No. 14/089,434 filed on Nov. 25, 2013 (now U.S.Pat. No. 9,051,120), U.S. patent application Ser. No. 14/733,341 filedon Jun. 8, 2015 the disclosures of which are incorporated herein byreference in their entireties.

One or more central system control computers (e.g. control server) 120may coordinate or otherwise control the operation of the multilevelvertical conveyors 150A, 150B with other suitable features of thestorage and retrieval system 100 in a manner substantially similar tothat described in U.S. patent application Ser. No. 12/757,337 filed onApr. 9, 2010 (now U.S. Pat. No. 8,594,835), and U.S. patent applicationSer. No. 12/757,220 filed on Apr. 9, 2010 (now U.S. Pat. No. 9,096,375),the disclosures of which are incorporated herein by reference in theirentireties. For example, the control server 120 may control theoperation of the storage and retrieval system 100 through, for example,any suitable communications network 180.

The storage structure 130 of the embodiments may be arranged such thatif desired there is substantially no vertical or horizontal arraypartitioning of the storage structure. For example, each multilevelvertical conveyor 150A, 150B may be common to all or substantially allstorage spaces (e.g. the array of storage spaces) in the storagestructure 130 such that any bot 110 can access each storage space andany multilevel vertical conveyor 150A, 150B can receive case units fromany storage space on any level so that the multiple levels in the arrayof storage spaces substantially act as a single level (e.g. no verticalpartitioning). Conversely case units from any shelf of each multilevelvertical conveyor 150A, 150B can be transferred to any or each storagespace throughout the storage structure or to each storage space of anylevel of the storage structure. The multilevel vertical conveyors 150A,150B can also receive case units from any storage space on any level ofthe storage structure 130 (e.g. no horizontal partitioning). Suitableexamples of multilevel vertical conveyors can be found in, fornon-limiting exemplary purposes, U.S. patent application Ser. No.12/757,354, filed on Apr. 9, 2010 and U.S. patent application Ser. No.12/757,220 filed on Apr. 9, 2010 (now U.S. Pat. No. 9,096,375), thedisclosures of which are incorporated herein by reference in theirentireties.

Referring now to FIG. 2A, the multilevel vertical conveyors will bedescribed in greater detail. It is noted that the input multilevelvertical conveyor 150A and associated in-feed transfer stations 170 aredescribed, however, the out-feed multilevel vertical conveyors 150B, bottransfer stations 140B and out-feed transfer stations 160 may besubstantially similar to that described below for their in-feedcounterparts but for the direction of material flow out of the storageand retrieval system 100 rather than into the storage and retrievalsystem 100. As may be realized, the storage and retrieval system 100 mayinclude multiple in-feed and out-feed multilevel vertical conveyors150A, 150B that are accessible by, for example, bots 110 on each levelof the storage and retrieval system 100 so that one or more case unit(s)can be transferred from a multilevel vertical conveyor 150A, 150B toeach storage space on a respective level and from each storage space toany one of the multilevel vertical conveyors 150A, 150B on a respectivelevel. The bots 110 may be configured to transfer the case units (aloneor in combinations) between the storage spaces and the multilevelvertical conveyors with one pick (e.g. substantially directly betweenthe storage spaces and the multilevel vertical conveyors). The caseunit(s) (which may be uncontained) being so transferred at one time(e.g. as a unit) may be referred to generally as a pickface. By way offurther example, the designated bot 110 picks the case unit(s) orpickface from a shelf of a multilevel vertical conveyor, transports thecase unit(s) to a predetermined storage area of the storage structure130 and places the case unit(s) or pickface in the predetermined storagearea (and vice versa).

Generally, the multilevel vertical conveyors include payload shelves 730(FIGS. 2A-4) attached to chains or belts that form continuously movingor circulating vertical loops (the shape of the loop shown in the Figs.is merely exemplary and in the embodiments the loop may have anysuitable shape including rectangular and serpentine) that move at asubstantially constant rate, so that the shelves 730 use what may bereferred to as the “paternoster” principle of continuous conveyance,with loading and unloading performed at any point in the loop withoutslowing or stopping. In the embodiments, it should be understood thatthe payload shelves 730 can be driven by any suitable drive mechanismsuch as tracks, gears, etc. The multilevel vertical conveyors 150A, 150Bmay be controlled by a server, such as for example, control server 120,or any other suitable controller. One or more suitable computerworkstations 700 may be connected to the multilevel vertical conveyors150A, 150B and the server 120 in any suitable manner (e.g. wired orwireless connection) for providing, as an example, inventory management,multilevel vertical conveyor functionality and control, and customerorder fulfillment. As may be realized, the computer workstations 700and/or server 120 may be programmed to control the in-feed and/orout-feed conveyor systems. In the embodiments, the computer workstations700 and/or server 120 may also be programmed to control the transferstations 140. In the embodiments, one or more of the workstations 700and control server 120 may include a control cabinet, a programmablelogic controller and variable frequency drives for driving themultilevel vertical conveyors 150A, 150B. In the embodiments theworkstations 700 and/or control server 120 may have any suitablecomponents and configuration. In the embodiments, the workstations 700may be configured to substantially remedy any exceptions or faults inthe in-feed and/or out-feed conveyor systems substantially withoutoperator assistance and communicate fault recovery scenarios with thecontrol server 120 and/or vice versa.

Referring still to FIG. 2A and also to FIG. 4, in the embodiments, themultilevel vertical conveyors 150A may include a frame 710 configured tosupport driven members such as, for example, chains 720. The chains 720may be coupled to the shelves 730, which are movably mounted to theframe 710 such that the chains 720 effect substantially continuousmovement of the shelves 730 around the frame 710. In the embodiments,any suitable drive link, such as for example, belts or cables may beused to drive the shelves 730. Each shelf 730 may include, for example,supports 930 and a platform 900. The supports 930 may extend from theplatform 900 and be configured for attaching and mounting the shelf 730to, for example, one or more drive chains 720. The platform 900 mayinclude, for example, any suitably shaped frame 911, which in thisexample is generally “U” shaped (e.g. having lateral members connectedby a span member at one end), and any suitable number of spaced apartfingers 910 extending from the frame 911. The fingers 910 may beconfigured for supporting the pickfaces 750, 752 (FIG. 2B) where eachpickface comprises at least one uncontained case unit. In theembodiments, each of the fingers 910 may be removably fastened to aframe 911 for facilitating replacement or repair of individual fingers910. The fingers 910, frame 911 (and supports 930) may form an integralstructure or platform that defines the seating surface that contacts andsupports the uncontained case units. It is noted that the shelf 730illustrates only a representative structure and in the embodiments, theshelves 730 may have any suitable configuration and size fortransporting pickfaces 750, 752 as will be described further below. Asmaybe realized the fingers 910 of each of the one or more pickfacesupport stations A-D, define the seating surface against which the oneor more uncontained cases of each pickface are gated. As seen in FIG. 5,the pickfaces on the support station may have constraints to preventmovement of the pickface(s) relative to the support stations (A-D). Thespaced apart fingers 910 are configured to interface with, for example,a transfer arm or effector of the bots 110 and the in-feed transferstations 170 for transferring the loads 750, 752 between the multilevelvertical conveyor 150A and one or more of the transfer stations 170 andbots 110. In the embodiments, the spaced apart fingers 900 may beconfigured to interface with bot transfer stations 140 as describedbelow.

The multilevel vertical conveyors 150A may also include a suitablestabilizing device(s), such as for example, driven stabilizing chainsfor stabilizing the shelves 730 during vertical travel. In one example,the stabilizing devices may include chain driven dogs that are engagedto the shelves in both the upward and downward directions to form, forexample, a three point engagement with the shelf supports 930. The drivechains 720 for the shelves 730 and stabilizing devices may be drivinglycoupled to for example, any suitable number of drive motors under thecontrol of, for example, one or more of the computer workstations 700and control server 120. Further examples for effecting stability of theconveyor shelves 730 in the embodiments are described later in thespecification.

In the embodiments there may be any suitable number of shelves 730mounted and attached to the drive chains 720. As can be seen in FIG. 2Beach shelf 730 may be configured to carry, for exemplary purposes only,at least two separate pickfaces 750, 752 in corresponding positions A, Con the shelf 730 (e.g. a single vertical conveyor is functionallyequivalent to multiple individually operated conveyors arranged adjacentone another). In the embodiments, as can be seen in FIG. 5 the shelves730′ may be configured to carry, for exemplary purposes only, fourseparate pickfaces 750-753 in corresponding positions A-D. In theembodiments, each shelf may be configured to carry more or less thanfour separate loads. As described above, each pickface may comprise oneor more uncontained case units and may correspond to the load of asingle bot 110. As may be realized, the space envelope or area platformof each pickface may be different. By way of example, uncontained cases,such as those directly transported by the multilevel vertical conveyorshave various different sizes (e.g. differing dimensions). Also, as notedeach pickface may include one or more uncontained cases. Thus, thelength and width of each pickface carried by the multilevel verticalconveyors may be different. In the embodiments each pickface may bebroken between, for example, bots 110 where different portions of thepickface are transported by more than one bot 110 on, for example,different levels of the storage structure 130. As may be realized when apickface is broken each portion of the broken pickface may be consideredas a new pickface by the storage and retrieval system 100. For exemplarypurposes only, referring to FIGS. 3A, 3B the shelves 730 of themultilevel vertical conveyors 150A, 150B may be spaced from each otherby a predetermined pitch P to allow for placement or removal of loads810, 820 from the substantially continuously moving shelves 730 as willbe described below.

Referring now to FIG. 5, and as described above, the multilevel verticalconveyors, such as conveyor 150A are supplied with case units 1000 fromin-feed transfer stations 170 (FIG. 1). As described above, the in-feedtransfer stations 170 may include one or more of depalletizingworkstations, conveyors 240, conveyor interfaces/bot load accumulators1010A, 1010B and conveyor mechanisms 1030. As can be seen in FIG. 5,case units 1000 are moved from, for example depalletizing workstationsby conveyors 240. In this example, each of the positions A-D is suppliedby a respective in-feed transfer station. As may be realized, while thetransfer of case units is being described with respect to shelves 730′it should be understood that transfer of case units to shelves 730occurs in substantially the same manner. For example, position A may besupplied by in-feed transfer station 170A and position C may be suppliedby in-feed transfer station 170B. Referring also to FIG. 2A the in-feedtransfer stations 170A, 170B, for supplying similar sides of the shelf730 (in this example positions A and C, which are disposed side by side,form a first side 1050 of the shelf 730 and positions B and D, which aredisposed side by side, form a second side 1051 of the shelf 730), may belocated one above the other in a horizontally staggered stackedarrangement (an exemplary stacked arrangement is shown in FIG. 2A). Inthe embodiments, the stacked arrangement may be configured so that thein-feed transfer stations are disposed vertically in-line one above theother and extend into the multilevel vertical conveyors by differentamounts for supplying, for example, positions A and B or positions C andD where positions A and B (and positions C and D) are disposed one infront of the other, rather than side by side. In the embodiments, thein-feed transfer stations may have any suitable configuration andpositional arrangement. As can be seen in FIG. 5, the first side 1050and second side 1051 of the shelf 730 are loaded (and unloaded) inopposing directions such that each multilevel vertical conveyor 150A islocated between respective transfer areas 295A, 295B where the firstside 1050 interfaces with a transfer area 295B and the second side 1051interfaces with transfer area 295A.

In the embodiments, the accumulators 1010A, 1010B may be configured toform the case units 1000 into the individual pickfaces 750-753 prior toloading a respective position A-D on the multilevel vertical conveyor730. In the embodiments, the computer workstation 700 and/or controlserver 120 may provide instructions or suitably control the accumulators1010A, 1010B (and/or other components of the in-feed transfer stations170) for accumulating a predetermined number of items to form thepickfaces 750-753. The accumulators 1010A, 1010B may align the caseunits in any suitable manner (e.g. making one or more sides of the itemsflush, etc.) and, for example, abut the items together. The accumulators1010A, 1010B may be configured to transfer the pickfaces 750-753 torespective conveyor mechanisms 1030 for transferring the pickfaces750-753 to a respective shelf position A-D. In the embodiments theconveyor mechanisms 1030 may include belts or other suitable feeddevices for moving the pickfaces 750-753 onto transfer platforms 1060.The transfer platforms 1060 may include spaced apart fingers forsupporting the pickfaces 750-753 where the fingers 910 of the shelves730 are configured to pass between the fingers of the transfer platforms1060 for lifting (or placing) the pickfaces 750-753 from the transferplatforms 1060. In the embodiments, the fingers of the transferplatforms 1060 may be movable and serve to insert the pickfaces 750-753into the path of the shelves 730 in a manner similar to that describedbelow with respect to the bot transfer stations 140. In the embodimentsthe in-feed transfer stations 170 (and out-feed transfer stations 160)may be configured in any suitable manner for transferring case units(e.g. the pickfaces formed by the case units) onto or from respectivemultilevel vertical conveyors 150A, 150B.

It is noted that while the interface between the bot transfer stations140 and the multilevel vertical conveyors 150A, 150B are described itshould be understood that interfacing between the bots 110 and themultilevel vertical conveyors 150A, 150B occurs in a substantiallysimilar manner (e.g. as described in U.S. patent application Ser. No.12/757,312 filed on Apr. 9, 2010, (now U.S. Pat. No. 8,425,173),previously incorporated herein by reference in its entirety). Forexemplary purposes only, referring now to FIGS. 2B and 6A-6D, themultilevel vertical conveyors 150A transfer pickfaces 750, 752 from, forexample, the in-feed transfer stations 170 (or any other suitable deviceor loading system) to, for example, the bot transfer stations 140associated with each of the levels in the storage structure 130. Inother examples, the pickfaces 750, 752 may be transferred directly fromthe multilevel vertical conveyors 150A to the bots 110 as describedbelow. As may be realized, the bot transfer stations 140 are disposed onrespective levels of the storage structure adjacent the path of travelof the shelves 730 of a respective multilevel vertical conveyor 150A. Inthe embodiments, there may be a bot transfer station 140 correspondingto each of the positions A and C on the shelves 730 (and positions A-Dwith respect to shelf 730′). For example, a first bot transfer station140 may remove load 750 from position A on shelf 730 while another bottransfer station 140 may remove pickface 752 from position C on shelf730 and so on. In the embodiments, one bot transfer station 140 mayserve to remove or place case units in more than one position A, C onthe shelves 730. For example, one bot transfer station 140 may beconfigured for removing pickfaces 750, 752 from one or more of positionsA, C of shelf 730. In the embodiments, referring also to FIG. 5, one bottransfer station 140 may be configured for removing pickfaces 750, 752from one or more of positions A, C on a first side 1050 of the shelf730′ while another bot transfer station 140 may be configured to removepickfaces 751, 753 from one or more positions B, D on a second side 1051of the shelf 730′. In the embodiments the bot transfer stations 140 mayhave any suitable configuration for accessing any suitable number ofpositions A-D of the shelves 730, 730′.

Each bot transfer station 140 may include a frame 1100, one or moredrive motors 1110 and a carriage system 1130. The frame 1100 may haveany suitable configuration for coupling the bot transfer station 140 to,for example, any suitable supporting feature of the storage structure130, such as a horizontal or vertical support. The carriage system 1130may be movably mounted to the frame 1100 through, for example, rails1120 that are configured to allow the carriage system 1130 to movebetween retracted and extended positions as shown in FIGS. 6A and 6B.The carriage system 1130 may include a carriage base 1132 and fingers1135. The fingers 1135 may be mounted to the carriage base 1132 in aspaced apart arrangement so that the fingers 1135 extend from thecarriage base 1132 in a cantilevered fashion. It is noted that eachfinger 1135 may be removably mounted to the carriage base 1132 forfacilitating replacement or repair of individual fingers 1135. In theembodiments the fingers and carriage base may be of unitary one-piececonstruction. The fingers 1135 of the bot transfer stations 140 may beconfigured to pass between the fingers 910 (FIG. 4) of the shelves 730of the multilevel vertical conveyors 150A (FIG. 1) for removingpickfaces such as pickfaces 1150 (which may be substantially similar topickfaces 750-753) from the shelves 730. The bot transfer station 140may also include a load positioning device 1140 that retractably extendsbetween, for example, the spaced apart fingers 1135 in the direction ofarrow 1181 for effecting positioning of the pickfaces 1150 in apredetermined orientation relative to the bot transfer station 140. Inthe embodiments the carriage system 1130 may have any suitableconfiguration and/or components. The one or more drive motors 1110 maybe any suitable motors mounted to the frame 1100 for causing theextension/retraction of the carriage system 1130 and theextension/retraction of the positioning device 1140 in any suitablemanner such as by, for exemplary purposes only, drive belts or chains.In the embodiments, the carriage system and positioning device may beextended and retracted in any suitable manner.

In operation, referring also to FIGS. 2C, 2D, 3A and 3B, inboundpickfaces (e.g. pickfaces, which include one or more case units, thatare being transferred into the storage and retrieval system) such aspickface 1150 are loaded on and will circulate around the multilevelvertical conveyor 150A and be removed from a respective conveyor by, forexample, one or more bots 110 for placement in a storage area of thestorage structure (FIG. 8, Blocks 8000 and 8010). As will be describedfurther below, in the embodiments the input loading sequencing of caseunits onto the multilevel vertical conveyors 150A, 150B (e.g. such as atcorresponding feeder input sides of transfer stations 170 and bottransfer locations on respective storage levels) may be substantiallyindependent from the output or unloading sequence of the multilevelvertical conveyors 150A, 150B (e.g. such as at corresponding outputsides of transfer stations 160 and bot transfer locations on respectivestorage levels) and vice versa. In one example, the pickface 1150 may beloaded onto the shelves 730 during an upward travel of the multilevelvertical conveyor 150A and off loaded from the shelves 730 duringdownward travel of the multilevel vertical conveyor 150A. By way ofexample, multilevel vertical conveyor shelves 730 i and 730 ii (FIG. 2D)may be loaded sequentially, but when unloaded, shelf 730 ii may beunloaded before shelf 730 i. It is noted that the shelves 730 may beloaded through one or more cycles of the multilevel vertical conveyor.In the embodiments the pickfaces may be loaded or off loaded from theshelves 730 in any suitable manner. As may be realized, the position ofthe case units on the multilevel vertical conveyor shelf 730 defines thepickface position that the bot 110 picks from. Accordingly, as may berealized, shudder of the pickface conveyor is highly undesired,especially in that a pickface(s) may remain on the conveyor for morethan one cycle after being loaded. The bot may be configured to pick anysuitable load or pickface from the shelf 730 regardless of the pickfaceposition on the shelf 730 or the size of the pickface. In theembodiments, the storage and retrieval system 100 may include a botpositioning system for positioning the bot adjacent the shelves 730 forpicking a desired pickface from a predetermined one of the shelves 730(e.g. the bot 110 is positioned so as to be aligned with the pickface).The bot positioning system may also be configured to correlate theextension of a bot transfer arm with the movement (e.g. speed andlocation) of the shelves 730 so that the transfer arm is extended andretracted to remove (or place) pickfaces from predetermined shelves 730of the multilevel vertical conveyors 150A, 150B. For exemplary purposesonly, the bot 110 may be instructed by, for example, the computerworkstation 700 or control server 120 (FIG. 2A) to extend the transferarm into the path of travel of the pickface 1150. As the pickface 1150is carried by the multilevel vertical conveyor 150A in the direction ofarrow 860 fingers of the bot transfer arm (which may be substantiallysimilar to fingers 1135 of the bot transfer station 140) pass throughthe fingers 910 of the shelf 730 for transferring the pickface 1150 fromthe shelf 730 to the carriage system 1135 (e.g. the pickface 1150 islifted from the fingers 910 via relative movement of the shelf 730 andthe bot transfer arm). As may be realized, the pitch P between shelvesmay be any suitable distance for allowing the transfer of pickfacesbetween the multilevel vertical conveyor and the bots 110 while theshelves 730 are circulating around the multilevel vertical conveyor at asubstantially continuous rate. The bot transfer arm may be retracted (ina manner substantially similar to that shown in FIGS. 6C, 6D withrespect to the bot transfer station 140) so that the pickface 1150 is nolonger located in the path of travel of the shelves 730 of themultilevel vertical conveyor 150A. It is noted that in the embodiments,where the bot transfer stations 140 are used, the positioning device1140 may be extended through the fingers 1135 and the carriage system1130 (FIGS. 6A-6D) may be moved in the direction of arrow 1180 forabutting the pickface 1150 against the positioning device 1140 effectingpositioning of the pickface 1150 in a predetermined orientation relativeto, for example, the bot transfer station 140. The carriage system 1130may be fully retracted as shown in FIG. 6D for transfer of the pickface1150 to a bot 110.

Referring to FIGS. 2D and 3B, for transferring loads in the outbounddirection (e.g. moving pickfaces from or out of the storage andretrieval system) the bots 110 pick one or more pickface, such aspickface 1150, from a respective predetermined storage area of thestorage structure (FIG. 8, Block 8020). The pickfaces may be extendedinto the path of the shelves 730 of the multilevel vertical conveyor150B (which is substantially similar to conveyor 150A) by the transferarm of bot 110 through an extension of the bot transfer arm relative toa frame of the bot 110. It is noted that the pickfaces, such as pickface1150, may be placed on the multilevel vertical conveyor 150 in a firstpredetermined order sequence (FIG. 8, Block 8030). The firstpredetermined order may be any suitable order. The substantiallycontinuous rate of movement of the shelves 730 in the direction of arrow870 cause the fingers 910 of the shelf 730 to pass through the fingersof the bot transfer arm such that the movement of the shelf 730 effectslifting the pickface 1150 from the fingers of the bot transfer arm. Thepickface 1150 travels around the multilevel vertical conveyor 150B to anout-feed transfer station 160 (which is substantially similar to in-feedtransfer station 170) where it is removed from the shelf 730 by aconveyor mechanism 1030 in a manner substantially similar to thatdescribed above. The pickfaces may be removed from the multilevelvertical conveyor 150B by, for example the out-feed transfer stations160 in a second predetermined order sequence that may be different andindependent from the first predetermined order sequence (FIG. 8, Block8040). The second predetermined order sequence may depend on anysuitable factors such as, for example, the store plan rules describedbelow. As noted before, to effect transfer of pickface(s) betweenconveyor stations and bot transfer arm or transfer station in a robotrepeatable manner where pickface size and shape may vary with eachtransfer it is desired that the motion of the pickface(s) on theconveyor be substantially free of shudder of judder.

It is noted that the respective transfer of pickfaces between themultilevel vertical conveyors 150A, 150B and the in-feed and out-feedtransfer stations 170, 160 may occur in a manner substantially similarto that described above with respect to the bots 110 and bot transferstations 140. In the embodiments transfer of pickfaces between themultilevel vertical conveyors 150A, 150B and the in-feed and out-feedtransfer stations 170, 160 may occur in any suitable manner.

As can be seen in FIGS. 2C and 2D the shelves 730 of the multilevelvertical conveyors 150A, 150B are loaded and unloaded by the in-feed andout-feed transfer stations 170, 160 and the bots 110 from a common sideof the shelf 730. For example, the shelves are loaded and unloaded inthe common direction 999 (e.g. from only one side of the shelf 730). Inthis example, to facilitate loading the multilevel vertical conveyorfrom only one side of the shelf, the multilevel vertical conveyors 150A,150B circumscribe a respective one of the in-feed and out-feed transferstations 170, 160 so that the pickfaces 1150 travel around the in-feedand out-feed transfer stations 170, 160. This allows the in-feed andout-feed transfer stations 170, 160 to be placed on the same side of theshelves 730 as the bots 110 for transferring pickfaces (and the caseunits therein) to and from the multilevel vertical conveyors 150A, 150B.

It is noted that the control server 120 may be configured to order theremoval of case units from the storage and retrieval system for anysuitable purpose, in addition to order fulfillment. In the embodiments,the distribution (e.g. sortation) of case units in the storage andretrieval system is such that the case units in the conveyor can beprovided for delivery to a palletizing station in any suitable order atany desired rate using only two sortation sequences. The control server120 may also be configured to incorporate, for example, store plan ruleswhen fulfilling orders so that the cases are provided by the bots 110 torespective multilevel vertical conveyors 150B in a first predeterminedsequence (e.g. a first sortation of case units for optimizing theutilization and throughputs of the bots) and then removed from therespective multilevel vertical conveyors 150B in a second predeterminedsequence (e.g. a second sortation of case units for optimizing theutilization and throughput of a palletizing device and to permitarrangement of cases within the pallet in a manner optimized forfacilitating unloading and distribution at a retail delivery point orfacility) so that the case units may be placed on pallets or othersuitable shipping containers/devices) in a predetermined order forbuilding mixed pallets (see e.g. FIG. 8 described above). For example,in the first sortation of case units the bots 110 may pick respectivecase units (e.g. case unit) in any order. The bots 110 may traverse thepicking aisles and transfer deck (e.g. circulate around the transferdeck) with the picked item until a predetermined time when the item isto be delivered to a predetermined multilevel vertical conveyor 150B. Inthe second sortation of case units, once the case units are on themultilevel vertical conveyor 150B the case units may circulate aroundthe conveyor until a predetermined time when the items are to bedelivered to the out-feed transfer station 160. Referring to FIG. 7, itis noted that the order of case units delivered to the pallets maycorrespond to, for example, store plan rules 9000. The store plan rules9000 may incorporate, for example, an aisle layout in the customer'sstore or a family group of case units corresponding to, for example, aparticular location in the store where the pallet will be unloaded or atype of goods. The order of case units delivered to the pallets may alsocorrespond to characteristics 9001 of the case units such as, forexample, compatibility with other case units, dimensions, weight and adurability of the case units. For example, crushable case units may bedelivered to the pallet after heavier more durable case units aredelivered to the pallet. The first and second sortations of the caseunits allow for the building of mixed pallets 9002 as described below.

The control server 120 in combination with the structural/mechanicalarchitecture of the storage and retrieval system enables maximum loadbalancing. As described herein, the storage spaces/storage locations aredecoupled from the transport of the case units through the storage andretrieval system. For example, the storage volume (e.g. the distributionof case units in storage) is independent of and does not affectthroughput of the case units through the storage and retrieval system.The storage array space may be substantially uniformly distributed withrespect to output. The horizontal sortation (at each level) and highspeed bots 110 and the vertical sortation by the multilevel verticalconveyors 150B substantially creates a storage array space that issubstantially uniformly distributed relative to an output location fromthe storage array (e.g. an out-feed transfer station 160 of a multilevelvertical conveyor 150B). The substantially uniformly distributed storagespace array also allows case units to be output at a desiredsubstantially constant rate from each out-feed transfer station 160 suchthat the case units are provided in any desired order. To effect themaximum load balancing, the control architecture of the control server120 may be such that the control server 120 does not relate the storagespaces within the storage structure 130 (e.g. the storage array) to themultilevel vertical conveyors 150B based on a geographical location ofthe storage spaces (which would result in a virtual partitioning of thestorage spaces) relative to the multilevel vertical conveyors 150B (e.g.the closest storage spaces to the multilevel vertical conveyor are notallocated to cases moving from/to that multilevel vertical conveyor).Rather, the control server 120 may map the storage spaces uniformly toeach multilevel vertical conveyor 150B and then select bots 110, storagelocations and output multilevel vertical conveyor 150B shelf placementso that case units from any location in the storage structure come outfrom any desired multilevel vertical conveyor output (e.g. at theout-feed transfer stations) at a predetermined substantially constantrate in a desired order for building the mixed pallets 9002.

Referring now to FIGS. 9A and 9B, there is shown feed station 141 inaccordance with the embodiments. In addition to the features describedbelow, station 141 may be substantially similar to out-feed and in-feedstations 160, 170. Feed station 141 may be an automated device that canbe configured to either transfer payloads referred to as pickfaces,cases or otherwise into an MVC and onto a platform or out of an MVC fromthe platform. In one example, the feed station 141 interfaces, forexample, the pickface builder 2010 (FIGS. 10-12) to the shelves 731(FIG. 13) of the multilevel vertical conveyor(s) 150 (FIG. 10). In theembodiments, feed station 141 may be used to transfer material to orfrom any suitable device, station or otherwise. In one example, the feedstation 141 receives a pickface from the pickface builder 2010. The feedstation may have any suitable pickface positioning features thatposition a reference datum (e.g. pickface datum) of the pickface(relative to a transfer device of the feed station) at a predeterminedposition on the multilevel vertical conveyor shelf 731 so that the bots110 (FIG. 1) can pick the pickfaces from the shelf 731. It is noted thatthe pickface datum relates the pickface to a placement position of thecases that form the pickface along a storage surface, such as e.g. thestorage shelves 600, of the storage and retrieval system. The transferdevice of the feed station 141 may translate to effect the handoff ofthe pickface to the shelf 731. In the embodiments the handoff may occurin any suitable manner. The feed station 141 may have any suitablecontroller to operate the transfer device in a predetermined sequencewith the multilevel vertical conveyor 150 and interact with the pickfacebuilder 2010.

Feed station 141 has driven roller bed 2112 to transfer in the x-axis2014. Feed station 141 has a set of extendable or retractable fingersand payload bed 2020 that traverses in the y-axis 2022 and PLC withcontrols 2030. Rollers 2012 may be selectively driven by drive motor andtransmission 2040 where sensors may be provided to detect the presence,edges or otherwise of the payload to be transported and used inconjunction with encoders or otherwise with controller 2030 to positionthe payload as desired. Gear motor 2050 may be provided to selectivelytraverse bed 2020 in the y direction 2022. A z axis drive (not shown)may be provided to move bed 2020 in the z direction 2024 to effect apick or place to rollers 2012. Feed station's 141 y-axis motion may becoordinated to transfer loads, for example, payloads, cases or otherwisefrom or onto the MVC platforms 730, 731 by positioning feed stationfingers 2020 to accept or pass off the payload to or from the platform730, 731. Feed station 141 transfers the payload between x and y-axis2014, 2022 through a z-axis 2024 lift of the fingers 2020. With apickface payload on rollers 2012, once fingers 2020 are lifted, a y-axismove in direction 2022, that may extend fingers 2020, may take place toallow the payload to be transported to the appropriate MVC (in a mannersimilar to that shown in FIG. 5). An opposite sequence may take placewhen transferring a payload from an MVC platform, for example, platform730 or 731 as will be described, to feed station 141 where fingers 2020retract in the y-axis direction 2022 and then lower in the z-axisdirection 2024 to transfer a pickface payload to the roller bed 2012 forremoval. As such, feed station 141 provides for an automated device thatcan be configured to either transfer payloads or cases into an MVC andonto a platform or out of an MVC from the platform. As may be realized,the pickface payload being output by an output MVC from the storage andretrieval system different than the input pickface payload. For example,as input pickface transported and loaded to a corresponding storagespace in the storage structure and comprising more than one case(s) maybe portioned during retrieval so that a sub-set of the input pickfaceare retrieved, and the retrieved pickface is different than the inputpickface.

Referring now to FIGS. 10-14C there is shown pickface builderarrangement 2002 having pickface builder 2010 and feed station 141.Pickface builder 2010, which may hereinafter be referred to as PFB maybe an automated device to align a single or multiple cases or pickfaceunits to form the single or multiple pickface payload for picking,placing or otherwise to be transferred in any suitable direction orotherwise and to be used in conjunction with any suitable conveyance,transport device or otherwise. Although pickface builder 2010 may bedescribed with respect to transfer station 141, pickface builder 2010may be utilized with or without any transfer station, transport systemor otherwise. Further, more or less features may be provided withpickface builder 2010. For example, transport features such asassociated with transfer station 141 or otherwise may be incorporatedinto pickface builder 2010 and more or less sensing, alignment or othersuitable features may be provided.

The pickface builder 2002 may be located in any suitable area of thestorage and retrieval system 100 in-feed conveyance system. In oneexample, the pickface builder 2010 may be located between the conveyor240 (see also FIG. 5) and the multilevel vertical conveyor 150. Forexample, in the embodiments the pickface builder 2010 may be arrangeddownstream from (e.g. adjacent to or offset from) a turn in elbow 240Eof the conveyor 240 (e.g. to change a direction of the flow of cases forinterfacing with the multilevel vertical conveyor 150) and upstream ofthe feed station 141. In the embodiments, the conveyor 150 may not havea turn in elbow in which case the pickface builder may interface with asubstantially straight conveyor. In the embodiments the pickface buildermay be located downstream the multilevel vertical conveyors and upstreamof a bot interface where the pickfaces are transferred to the bots. Thepickface builder 2010 may be configured to arrange and compile a set(e.g. one or more) of cases to build a pickface of cases (e.g. containedor uncontained cases). Each pickface is picked (as a unit) by bots 110for placement and retrieval in the storage racks of the storagestructure 130 and/or the shelves 731 of the multilevel verticalconveyors 150. In the embodiments shown in the figures the pickfacebuilder 2010 communicates with the multilevel vertical conveyors 150through the feed station 141 so that pickfaces are transferred (as aunit) to the multilevel vertical conveyors 150 after the pickface isbuilt. In the embodiments, each pickface builder 2010 may be linked to adedicated position of the multilevel vertical conveyor shelves 731, suchas where the shelves 731 have more than one pickface holding location2280, 2290 (FIG. 13). In the embodiments each pickface builder may beconfigured to selectively feed cases to each pickface holding location2280, 2290 of the shelves 731 (e.g. a common pickface builder for one ormore shelf positions). In the embodiments, the pickface builder 2010 mayadjoin a side of a respective feed station 141 and be disposed so thatcases of the pickface exit the pickface builder, through any suitabledrive unit, and enter the feed station 141 in a direction that is angled(e.g. substantially orthogonal) relative to the direction in which thefeed station transfers the pickface to the multilevel vertical conveyor.In the embodiments, the cases may be arranged at any suitable anglerelative to the direction or travel of the pickface from the feedstation 141 to the multilevel vertical conveyor 150.

Pickface builder 2010 may have x-y axis pusher 2100 (or a single axis,e.g. y axis, pusher), y-axis snugger 2120, roller bed 2140 and PLCcontrols 2160. In one example, the pusher 2100 may have any suitabletype and number of pusher plates 2100P for pushing cases across asupport surface (which may be movable) of the pickface builder 2010. Thepusher plate(s) 2100P may be resilient and may be positioned to engagecases such that the cases can be pushed as they move along the directionof travel on the conveyor 240 (e.g. the pusher 2100 is configured todrive the pusher plates 2100P along the x and y directions) forpositioning cases on the pickface builder 2010 for building thepickface. The x-y axis pusher 2100 may be located to receive cases suchthat the direction of the flow of cases from the conveyor 240 is towardsthe pusher (e.g. the conveyor discharges cases substantially in front ofor adjacent the pusher). In one example, the case configuration uponreceipt by the pusher 2100 may be such that a long axis of the cases isoriented to interface with the pusher 2100. In another example, theshort axis of the cases may be oriented to interface with the pusher2100 (e.g. the cases may have any suitable orientation relative to thepusher 2100). In still other examples, the cases may have mixedorientations when interfacing with the pusher 2100 (e.g. some casesinterface the pusher via a long axis of the case and other casesinterface with the pusher via the short axis of the case). The x-y axispusher 2100 directs cases from the conveyor 240 towards the snugger2120.

The snugger 2120 includes any suitable type and number of snugger plates2120P that are positioned substantially opposite the pusher 2100 andsubstantially transverse to the direction of case travel between, forexample, feed station 141 and the multilevel vertical conveyor 150. Inone example, the snugger establishes a pickface pick datum. For example,the snugger 2120 may be movable in at least the y direction (e.g.towards the pusher plate 2100P) to establish a pickface datum referencewhen, for example, the pusher 2100 pushes cases up against the snugger2120 (or vice versa) for substantially aligning and snugging the cases(that form a pickface) together. In one example, the snugger 2120 may bespring loaded in any suitable manner. In the embodiments the snugger maynot be spring loaded. The pickface builder 2010 transfers to andcollates the aligned cases (e.g. pickfaces) on the feed station 141 forsubsequent transfer to the multilevel vertical conveyor 150. In oneexample, the pickface builder operates so that the snugger 2120 receivesan initial case of the pickface and other cases of the pickface areabutted against the initial case as will be described below. In theembodiments the cases of the pickface may be arranged so that one ormore cases of the pickface are in substantial contact with the snuggerplate 2120P for establishing the pickface datum reference.

Pickface builder pusher 2100 and snugger 2120 have linear actuators2162, 2164, 2166 driven by servo motors. In the embodiments, anysuitable actuator, linear or otherwise may be provided, for example, anysuitable other linear motion technologies. In the embodiments, PFBmotion is triggered by a sensor 2170 in the pusher 2100, which follows apayload or case throughout travel of pusher 2100 to provide positivepresence detection throughout the x-y motion of pusher 2100. PFB 2010uses gate 2180 to halt x-axis motion of the payload until the fullpickface has been built and snugged where the pickface may consist ofone or more cases or payloads and where the snugging may consist ofpositioning cases or payloads adjacent one another or at any suitablelocation with respect to each other. Here, pickface builder 2010 pusher2100 moves in an x-y motion profile that varies (depending on physicalcharacteristics of the payload including, but not limited to, casedimensions, mass, packaging materials and fragility) and the PFB snugger2120 moves in a y-axis profile which may be normal to the direction ofpayload travel or otherwise that varies depending on an aggregate of allpayload or case dimensions in a given pickface. PFB snugger 2120 maycompress all payloads or as is in the pickface in the y-axis to presenta compact aggregate of payloads for picking, placing or subsequenttransport. PFB roller bed 2140 may be a motor driven conveyor thatprovides payload or case motion in the x-axis. In the embodiments, anysuitable form of conveyor such as belt, or a static bed with other meansof x-axis conveyance may be provided for use in conjunction with pusher2100 and/or snugger 2120. As such, pickface builder 2010 may provide anautomated device to align multiple payloads or cases to present theaggregate for picking, placing or otherwise transferring to or from MVC150A, B or C or other suitable transport device.

The pickface builder 2010 may be connected to, for example, any suitablecontroller such as a programmable logic controller, micro-controller orcontrol server 120 in any suitable manner. In the embodiments,information from, for example, the control server 120 identifies anysuitable ID (identification) data (e.g. SKU numbers, case dimensions,etc.) for each of the incoming cases (e.g. cases being placed on andtravelling on conveyor 240). For exemplary purposes only, the ID datamay be case specific (such as with the SKU numbers) and may also relateto storage parameters such as for example, a storage location within thestorage and retrieval system the cases are to be stored and/orparticulars for the pickface (e.g. case orientation, contents of apickface, pickface configuration, etc.). In the embodiments the case IDdata may be any suitable data related to the cases and/or the storage ofthe cases within the storage and retrieval system. The case ID data(including, but not limited to, SKU numbers, storage parameters,pickface contents, case dimensions etc.) may be stored locally such aswithin a memory of the pickface builder 2010 or within a memory of, forexample, the control server 120 or any other suitable controller. Thecase ID data may be stored in any suitable format such as in lookuptables. The controller, such as controller 120 or any other suitablecontroller, generates, for example, an x, y movement profile of thepusher 2100 and/or a y offset of the snugger 2120 to, for example,establish the datum of the pickface based on any suitable data such asthe case ID data or updated data from any suitable sensors (such asinfeed resolver 2999) placed along the infeed path of the cases (e.g.along conveyor 240 or any other suitable area of the storage andretrieval system).

In one example, the infeed resolver 2999 may be configured to confirmthe ID data of the incoming cases. The data obtained from, for example,the infeed resolver (such as, for example, the case dimensions and/orany other suitable case information) may be transmitted in any suitablemanner to the pickface builder 2010 (e.g. directly to the pickfacebuilder or through, for example, control server 120) so that the motionprofiles of the pusher 2100 and snugger 2120 are updated to correspondto any observed variances of the cases (with respect to, for example,predetermined case values stored in, for example, the control server orany other suitable controller) as determined by the infeed resolver2999. In the embodiments, the pickface builder 2010 may be configured inany suitable manner to redirect or discard cases that are determined tobe erroneous based on predetermined case data (e.g. expected case data)and, for example, actual case data obtained from the resolver 2999. Inthe embodiments a separate case inspection station may be providedadjacent the pickface builder 2010 for redirecting and discarding cases.In one example, the pickface builder 2010 may have a gate or otherselectably operable unit for removing the erroneous cases from thepickface builder 2010.

As described above, the pickface builder 2010 may be configured tocommunicate in any suitable manner with, for example, the control server120 and also a controller 150PLC of an associated multilevel verticalconveyor(s) 150. The pickface builder 2010 may obtain information fromthe controller 150PLC and/or the control server 120 as to which shelves731 (see e.g. FIG. 13) of the multilevel vertical conveyor 150 areoccupied (e.g. have pickfaces located on the shelves). The pickfacebuilder 2010 may be configured so that pickfaces are not fed to feedstation 141 unless an empty shelf 731 is provided on the multilevelvertical conveyor to which the pickface will be transferred. In theembodiments, the pickface builder may be in communication with the feedstation 141 so that when a pickface is transferred from the pickfacebuilder 2010 to the feed station 141 the feed station 141 will nottransfer the pickface to the multilevel vertical conveyor unlessinstructed to by the pickface builder 2010. In one example, the pickfacebuilder may be configured to receive data from, for example, themultilevel vertical conveyor 150 and or control server 120 for trackingpickfaces that are transferred to the multilevel vertical conveyor 150.For example, when a pickface is transferred to the multilevel verticalconveyor 150 an identification of the shelf 731 to which the pickface istransferred may be communicated to the pickface builder 2010 so that thepickface builder knows where each pickface is on the multilevel verticalconveyor 150 and which shelves 731 are empty. As another example, inaddition to or in lieu of communicating the identification of the shelfto the pickface builder, an identification of the pickface iscommunicated to the conveyor so that the conveyor knows which pickface,if any, is on each conveyor shelf. As each pickface is removed from themultilevel vertical conveyor 150 the pickface builder 2010 and/or themultilevel vertical conveyor 150 may receive data that indicates theshelf from which the pickface was taken is now empty and available toreceive another pickface(s). In the embodiments, the status of themultilevel vertical conveyor shelves may be tracked in any suitablemanner (such as with, e.g. any suitable sensing devices disposed along apath of the conveyor shelves 731).

In one exemplary operation of the pickface builder (and in-feed conveyorsystem) cases such as cases 1301, 1302 travel along conveyor 240 in thedirection of arrow 1399 towards the pickface builder 2010 (FIG. 13A).The pusher 2100 pushes, for example, a first case 1301 of a pickfacetowards the snugger 2120 so that the case 1301 is in substantial contactwith the snugger 2120 (FIG. 13B). The snugger may also move towards thepusher 2100 to, for example, establish the pickface reference datum. Thepusher retracts in the direction of arrows 1388, 1389 away from the case1301 and returns to its initial position (FIGS. 13C and 13D) so that asecond case 1302 of the pickface can be pushed up against (e.g. snugged)against case 1301 (FIGS. 13E and 13D). As may be realized, as the casesare pushed by the pusher 2100 the pusher may move two-dimensionally sothat the cases being pushed are also travelling in the direction oftravel along the conveyor 240 (e.g. in the direction of arrow 1399). Inthis example cases 1301, 1302 form pickface 1350 (FIG. 13G) which isheld on the pickface builder by gate 2180 until an open shelf of themultilevel vertical conveyor 150 is available. The gate 2180 may belowered or otherwise moved so that the pickface 1350 is driven off ofthe pickface builder 2010 in any suitable manner and onto the feedstation 141. The feed station may be arranged to transfer the pickfacein one or more directions A13, B13 (FIG. 13H), depending on a locationof one or more multilevel vertical conveyors 150 for transferring thepickface 1350 to a desired shelf 731 (FIG. 15). As may be realized, asthe pickface 1350 is being moved off of the pickface builder anotherpickface may start to form such that case 1303 (the next case in theline of cases moving along the conveyor 240) is moved adjacent thepusher 2100 so that pickfaces are substantially continuously beingbuilt.

FIGS. 14A-14C illustrate another exemplary formation of a pickface butwith smaller cases 1401-1402. In this example cases 1401-1403 are shownmoving along the conveyor 240. The formation of the pickface of FIGS.14A-14C occurs in substantially the same manner as that described abovewith respect to FIGS. 13A-13H. It is noted that all dimensions and timeinformation shown in FIGS. 13A-14C are exemplary only and that anysuitable dimensions and time values can be used.

Referring now to FIG. 15, there is shown an exemplary platform 731 ofthe MVC. In addition to the features described below, platform 731 mayhave similar features as described previously with respect to shelf orplatform 730. Referring also to FIGS. 16 and 17, there is shown MVC 150Chaving platform guides 2200. In addition to the features describedbelow, MVC 150C may have similar features as described with respect toMVC 150A or MVC 150B. In the embodiments platform 731 has guide wheels2210, 2220, 2230 and 2240 mounted to frame 2250. In the embodiments, anysuitable guide interface (e.g. single or multiple rollers, bearings),may be used in place of wheels. Chain couplers 2260 and 2270 areprovided between rollers 2210, 2230 and frame 2250 respectively. Payloadsupport surfaces 2280 and 2290 are provided coupled to frame 2250.Though the payload support surfaces or stations are shown, the platformmay have more or fewer in the embodiments. MVC 150C has suitable motordrive 2300 which drives chain drives 2310 and 2320 (through shaft 2330which in turn drive chain systems 2335 and 2340 respectively). Platform731 may be coupled to chain systems 2335 and 2340 with couplings 2270and 2260 respectively. Although guides 2200 are shown for the upperportion of MVC 1500, similar features may be provided on a lower portionof MVC 150C to provided continuous guidance of platform 731. Although asingle platform 731 is shown on MVC 150C, multiple platforms may beprovided at a common or multiple intervals. Guides 2200 are shown havinggenerally four guide portions 2350, 2360, 2370 and 2380 corresponding toguide rollers 22210, 2220, 2230 and 2240 respectively and coupled toframe 2205 of MVC 150C. Guides 2350 and 2370 are provided offset at awider stance with respect to guides 2360 and 2380. Guides 2350 and 2370provide substantially continuous guidance of rollers 2210 and 2230throughout the path of travel through MVC 1500 and with breaks at thecorners where sprockets in combination with chain couplings 2260 and2270 provide continued guidance of platform 731 and where the breaksprevent an over constraint. Guides 2360 and 2380 provide substantiallycontinuous guidance of rollers 2220 and 2240 throughout the path oftravel through MVC 150C and with breaks where couplings 2260 and 2270would interfere with guides 2360 and 2380 during passage and whereguides 2360 and 2380 provide continued guidance of platform 731 andwhere the breaks prevent interference but also where guide wheel 2220(see FIG. 15) is actively guided when guide wheel 2240 passes a breakand where guide wheel 2240 is actively guided when guide wheel 2220passes a break. As such, a substantially continuous three-point guidanceis accomplished during the entire path of travel. In the embodiments,one or more of the motor 2300 chain drives 2310, 2320 and chain systems2335, 2340 may include an active braking mechanism and velocity control.It is noted that the chain systems 2335, 2340 and the platformsgenerally revolve around the conveyor path at a substantially constantvelocity to, for example, allow the bots to rendezvous with a platform.The braking mechanism and/or velocity control may substantially preventthe platforms from “free-wheeling” (e.g. moving without being driven bythe motor 2300 and drive chains) if power is lost when a number ofplatforms are heavily loaded while others are substantially empty. Here,platform 731 travel may be guided by two sets of guide wheels 2210, 2220and 2230, 2240 that travel within channels 2350, 2360 and 2370, 2380 ona predetermined path defined by the channels and drive system. Hence,the guide wheels 2210, 2220, 2230, 2240 and correspondingly the platform(and pickface(s) supported thereby) traveling along the path resistbinding due to a balanced cantilevered arrangement and where transitionsthrough corners are made by substantially continuously having threepoints (wheels) of contact within the roller guides 2350, 2360, 2370,2380, providing smooth (substantially shudder/judder free) transition ofplatform 731 through the entire path of travel within MVC 150C. In theembodiments, one or more MVC(s) 150C enable loading and unloading ofpayloads, cases or pickfaces in storage racks of storage levels.

As noted before, MVC platforms 731 may have more than one pickfacestation, for example, for pickfaces of at least one case(s). Platforms731 are cycled by chain drive 2335, 2340 and use guides 2200 such thatthe stations maintain stability capable of desired positioning ofpickfaces through substantially the full motion cycle within MVC 150Cand without over constraints that may cause shuddering, jamming or otherunsuitable or undesired motions of the pickface(s) to occur. Here, theMVC platform connection to MVC drive system 2260, 2270, and MVC platformguides 2200 are configured to effect three (3) point contact betweenplatform 731 and MVC structure through full motion cycle and withoutover constraints. The platform supports, formed by the guides 220 anddrive system coupling 2260, 2270 form what may be referred to as aguided cantilever restraint that is movable through complete cyclewithout over-constraints, and, as a result without undesirable motion,such as shudder or judder through cycle motion. Accordingly a smooth andeffective load and unload MVC cycle (e.g. infeed to off load for infeedMVC and vice versa for outfeed MVC) as well as MVC sorter (e.g. pickfacepayload moves through more than one cycle) may be provided. In theembodiments, MVC 150C has frame 2205, drive system 2300 and platforms731 that are mounted to the frame and coupled to the drive system 2300so the platforms 731 are cycled vertically in a closed loop. Platform(s)731 may have one or more pickface payload holding stations (e.g. two2280, 2290) that are located offset from each other, for example,positionally distributed on platform. In the embodiments, more or lesslocations may be provided. Each holding station may be configured forholding pickface of (one or more) uncontained cases(s). Each holdingstation may independently fed and offloaded. Independent feeds may havepickface builders that may be accommodated by MVC structure and motionpath profile(s). Further, MVC 150C may be both a multilevelloader/unloader and sorter. In the embodiments, frame 2205 and drive2300 may be configured to effect platform 731 motion that results in avertical or horizontal cycle component in a same direction asload/unload transfer axis for a given pickface, for example, front-back.In the embodiments, the interface may be to warehouse conveyors, forexample, a load station for infeed to MVC 150C or an unload station foroutfeed from MVC 150C as may be located interior to frame 2205 andtransport loop path of platforms 731 of MVC 150C. Interface with rackstorage and retrieval system, for example, bot to MVC transfer locationsmay be provided on an outside of the transport loop path of platforms731 of MVC 150C. In the embodiments, any suitable in feed or out feedmay be provided on the inside, outside or otherwise of the transportpath of platforms 731 of MVC 150C.

In a first aspect of the embodiments a pickface builder for a storageand retrieval system for storing goods units and having an in-feedconveyor and a picking device is provided. Each goods unit holds atleast one product package therein. The pickface builder includes aframe, a pusher member movably coupled to the frame, and a snuggermember movably coupled to the frame, wherein the pickface builder isconfigured to receive goods units from the in-feed conveyor and thepusher member and snugger member are movable at least in a directiontransverse to a direction of goods unit travel on the in-feed conveyorand configured to form the goods units into a pickface picked by thepicking device as a unit and having a predetermined reference datumrelating the pickface to a placement position of goods units forming thepickface along a storage surface of the storage and retrieval system.

In accordance with a first sub-aspect of the first aspect of theembodiments the pusher member may be movable in at least two orthogonaldirections for pushing the goods units towards the snugger member.

In accordance with the first sub-aspect of the first aspect of theembodiments, the snugger member is positioned to create thepredetermined reference datum as the pusher member pushes goods unitstowards the snugger member.

In accordance with the first aspect of the embodiments, the pickfacebuilder further includes a movable gate disposed adjacent the snuggermember for retaining at least one goods unit as a pickface is formedfrom the at least one goods unit.

In accordance with a second sub-aspect of the first aspect of theembodiments, the pickface builder further includes a resolver memberconfigured to obtain case goods unit as goods units are transferred tothe pickface builder from the in-feed conveyor.

In accordance with the second sub-aspect of the first aspect of theembodiments, the pickface builder is configured to form pickfaces basedon at least the goods unit data obtained from the resolver member.

In accordance with the second sub-aspect of the first aspect of theembodiments, the resolver member is configured to confirm an identity ofthe goods units being transferred to the pickface builder from thein-feed conveyor.

In accordance with the second sub-aspect of the first aspect of theembodiments, the pickface builder is configured to modify motionprofiles of at least one of the pusher member and snugger member basedon the goods unit data from the resolver member.

In accordance with the first aspect of the embodiments, the pickfacebuilder further comprises a controller in communication with acontroller of the picking device, the controller being configured toassociate pickfaces with shelves of the picking device for tracking aposition of the pickfaces on the picking device.

In accordance with a third sub-aspect of the first aspect of theembodiments, the pickface builder includes a controller configured tocreate motion profiles for the pusher member and snugger member based atleast on predetermined goods unit data accessible by the controller.

In accordance with the third sub-aspect of the first aspect of theembodiments, wherein the controller includes a memory configured tostore the predetermined goods unit data.

In accordance with the third sub-aspect of the first aspect of theembodiments the storage and retrieval system includes a systemcontroller wherein the pickface builder is in direct or indirectcommunication with the system controller and the predetermined goodsunit data is stored in a memory of the system controller.

In accordance with a fourth sub-aspect of the first aspect of theembodiments the pickface is formed from uncontained goods units.

In accordance with the fourth sub-aspect of the first aspect of theembodiments the pickface is a surface of the uncontained goods unitsforming the pickface.

In a second aspect of the aspect of the embodiments a storage andretrieval system is provided. The storage and retrieval system includesan in-feed conveyor, an in-feed station, a pickface builder disposedbetween the in-feed conveyor and in-feed station, and picking deviceconnected to the in-feed station, the in-feed station being configuredto transfer goods units to the picking device where each goods unitholds at least one product package therein. The pickface builderincludes a frame, a pusher member movably coupled to the frame, and asnugger member movable coupled to the frame, wherein the pickfacebuilder is configured to receive goods units from the in-feed conveyorand the pusher member and snugger member are movable at least in adirection transverse to a direction of goods unit travel on the in-feedconveyor and configured to form the goods units picked by the pickingdevice as a unit into a pickface having a predetermined reference datumrelating the pickface to a placement position of goods units forming thepickface along a storage surface of the storage and retrieval system.

In accordance with the second aspect of the embodiments, the pickfacebuilder is located downstream of an elbow in the in-feed conveyor sothat the pusher member and snugger member are substantially transverseto a direction of travel of the goods units from the in-feed station tothe picking device.

In accordance with a first sub-aspect of the second aspect of theembodiments, the pickface builder further includes a controllerconfigured to create motion profiles for the pusher member and snuggermember based at least on predetermined goods unit data accessible by thecontroller.

In accordance with the first sub-aspect of the second aspect of theembodiments the controller includes a memory configured to store thepredetermined goods unit data.

In accordance with the first sub-aspect of the second aspect of theembodiments the storage and retrieval system includes a systemcontroller wherein the pickface builder is in direct or indirectcommunication with the system controller and the predetermined goodsunit data is stored in a memory of the system controller.

In accordance with a third aspect of the embodiments, a pickface builderfor a storage and retrieval system for storing goods unit and having anin-feed conveyor and a picking device is provided. Each goods unitholding at last one product package therein. The pickface builderincludes a frame, a pusher member movably coupled to the frame, and asnugger member movably coupled to the frame, wherein the pickfacebuilder is configured to receive goods units from the in-feed conveyorand the pusher member and snugger member are configured to form thegoods units into a pickface picked by the picking device as a unit andhaving a predetermined reference datum where the predetermined referencedatum depends on at least one predetermined pickface characteristic andrelates the pickface to a placement position of goods units forming thepickface along a storage surface of the storage and retrieval system.

In accordance with a first sub-aspect of the third aspect of theembodiments the pickface builder further includes a controllerconfigured to create motion profiles for the pusher member and snuggermember based on the at least one predetermined pickface characteristic.

In accordance with the first sub-aspect of the third aspect of theembodiments the controller is in direct or indirect communication with asystem controller of a storage and retrieval system and is configured toaccess the at least one predetermined pickface characteristic from amemory of the system controller.

It should be understood that the embodiments described herein may beused individually or in any suitable combination thereof. It should alsobe understood that the foregoing description is only illustrative of theembodiments. Various alternatives and modifications can be devised bythose skilled in the art without departing from the embodiments.Accordingly, the embodiments are intended to embrace all suchalternatives, modifications and variances within the scope of theappended claims.

What is claimed is:
 1. A pickface builder for a storage and retrievalsystem for storing goods units and having an in-feed conveyor and apicking device, each goods unit holding at least one product packagetherein, the pickface builder comprising: a frame; a pusher membermovably coupled to the frame; and a snugger member movably coupled tothe frame, wherein the pickface builder is configured to receive goodsunits from the in-feed conveyor and the pusher member and snugger memberare movable at least in a direction transverse to a direction of goodsunit travel on the in-feed conveyor and configured to form more than oneof the goods units into a pickface picked by the picking device as aunit and having a predetermined reference datum, formed by relativemovement between the pusher member and the snugger member, the relativemovement simultaneously creating the predetermined reference datum andits position reference embodied therein so that the position referenceof the predetermined reference datum embodies a structural positioningreference feature that defines a corresponding structural positioningreference feature intrinsic to the pickface and is common to the morethan one of the goods units forming the pickface, so as to relate eachof the more than one of the goods units forming the pickface to arespective placement position of each of the goods units forming thepickface and placed as a unit along a storage surface of the storage andretrieval system.
 2. The pickface builder of claim 1, wherein the pushermember is movable in at least two orthogonal directions for pushing thegoods units towards the snugger member.
 3. The pickface builder of claim2, wherein the snugger member is positioned to create the predeterminedreference datum as the pusher member pushes goods units towards thesnugger member.
 4. The pickface builder of claim 1, wherein the pickfacebuilder further comprises a movable gate disposed adjacent the snuggermember for retaining at least one goods unit as a pickface is formedfrom the at least one goods unit.
 5. The pickface builder of claim 1,wherein the pickface builder further comprises a resolver memberconfigured to obtain goods unit data as goods units are transferred tothe pickface builder from the in-feed conveyor.
 6. The pickface builderof claim 5, wherein the pickface builder is configured to form pickfacesbased on at least the goods unit data obtained from the resolver member.7. The pickface builder of claim 5, wherein the resolver member isconfigured to confirm an identity of the goods units being transferredto the pickface builder from the in-feed conveyor.
 8. The pickfacebuilder of claim 5, wherein the pickface builder is configured to modifymotion profiles of at least one of the pusher member and snugger memberbased on the goods unit data from the resolver member.
 9. The pickfacebuilder of claim 1, wherein the pickface builder further comprises acontroller in communication with a controller of the picking device, thecontroller being configured to associate pickfaces with shelves of thepicking device for tracking a position of the pickfaces on the pickingdevice.
 10. The pickface builder of claim 1, wherein the pickfacebuilder includes a controller configured to create motion profiles forthe pusher member and snugger member based at least on predeterminedgoods unit data accessible by the controller.
 11. The pickface builderof claim 10, wherein the controller includes a memory configured tostore the predetermined goods unit data.
 12. The pickface builder ofclaim 10, wherein the storage and retrieval system includes a systemcontroller wherein the pickface builder is in direct or indirectcommunication with the system controller and the predetermined goodsunit data is stored in a memory of the system controller.
 13. Thepickface builder of claim 1, wherein the pickface is formed fromuncontained goods units.
 14. The pickface builder of claim 13, whereinthe pickface is a surface of the uncontained goods units forming thepickface.
 15. A storage and retrieval system comprising: an in-feedconveyor; an in-feed station; a pickface builder disposed between thein-feed conveyor and in-feed station, and a picking device connected tothe in-feed station, the in-feed station being configured to transfergoods units to the picking device where each goods unit holds at leastone product package therein, the pickface builder includes a frame, apusher member movably coupled to the frame, and a snugger member movablecoupled to the frame, wherein the pickface builder is configured toreceive goods units from the in-feed conveyor and the pusher member andsnugger member are movable at least in a direction transverse to adirection of goods unit travel on the in-feed conveyor and configured toform more than one of the goods units picked by the picking device as aunit into a pickface having a predetermined reference datum, formed byrelative movement between the pusher member and the snugger member, therelative movement simultaneously creating the predetermined referencedatum and its position reference embodies therein so that the positionreference of the predetermined reference datum embodies a structuralpositioning reference feature that defines a corresponding structuralpositioning reference feature intrinsic to the pickface and is common tothe more than one of the goods units forming the pickface, so as torelate each of the more than one goods units forming the pickface to arespective placement position of each of the goods units forming thepickface and placed as a unit along a storage surface of the storage andretrieval system.
 16. The storage and retrieval system of claim 15,wherein the pickface builder is located downstream of an elbow in thein-feed conveyor so that the pusher member and snugger member aresubstantially transverse to a direction of travel of the goods unitsfrom the in-feed station to the picking device.
 17. The storage andretrieval system of claim 15, wherein the pickface builder furtherincludes a controller configured to create motion profiles for thepusher member and snugger member based at least on predetermined goodsunit data accessible by the controller.
 18. The storage and retrievalsystem of claim 17, wherein the controller includes a memory configuredto store the predetermined goods unit data.
 19. The storage andretrieval system of claim 17, wherein the storage and retrieval systemincludes a system controller wherein the pickface builder is in director indirect communication with the system controller and thepredetermined goods unit data is stored in a memory of the systemcontroller.
 20. A pickface builder for a storage and retrieval systemfor storing goods units and having an in-feed conveyor and pickingdevice, each goods unit holding at least one product package therein,the pickface builder comprising: a frame; a pusher member movablycoupled to the frame; and a snugger member movably coupled to the frame,wherein the pickface builder is configured to receive goods units fromthe in-feed conveyor and the pusher member and snugger member areconfigured to form more than one of the goods units into a pickfacepicked by the picking device as a unit and having a predeterminedreference datum, formed by relative movement between the pusher memberand the snugger member, the relative movement simultaneously creatingthe predetermined reference datum and its position reference embodiedtherein so that the position reference of the predetermined referencedatum embodies a structural positioning reference feature where thepredetermined reference datum depends on at least one predeterminedpickface characteristic and defines a corresponding structuralpositioning reference feature intrinsic to the pickface and is common tothe more than one of the goods units forming the pickface, so as torelate each of the more than one goods units forming the pickface to arespective placement position of each of the goods units forming thepickface and paced as a unit along a storage surface of the storage andretrieval system.